Assembly of Electronic Components for Electrical Rotating Machine

ABSTRACT

An assembly of electronic components for a rotary electrical machine and power and signal interconnection pieces cooperating with the electronic components in order respectively to distribute power to the electronic components and convey control signals between electronic components for the functioning of the rotary electrical machine, wherein the electronic components are disposed in at least one module disposed on a first plane, the at least one module comprising a housing defined by a top face and a bottom face and at least three lateral faces, the signal interconnection piece is disposed on a second plane parallel to the first plane, and the power interconnection piece is disposed on a third plane parallel to the first plane, the power and signal interconnection pieces being independent of each other and independent of the at least one module.

FIELD OF THE INVENTION

The invention concerns an arrangement of electronic components andassociated power and signal devices for a rotary electrical machine, thesaid machine integrating the said electronic components.

The present invention applies to any type of polyphase rotary electricalmachine, synchronous or asynchronous, such as alternators or alternatorstarters, and also whether it is a case of electrical machines for motorvehicles and driven for example by belt, with cooling by air, liquid orany other solution that can be envisaged.

BACKGROUND OF THE INVENTION

In a motor vehicle comprising a thermal engine and a rotary electricalmachine such as an alternator starter, such an electrical machinecomprises for example, non-limitatively:

a rotor comprising a field winding into which an excitation current isbrought, and

a stator comprising a polyphase winding.

The alternator starter functions in motor mode or in generator mode. Itis a so-called reversible machine.

In generator or alternator mode, the machine converts a rotationmovement of the rotor driven by the thermal engine of the vehicle intoan electric current induced in the phases of the stator. In this case, abridge rectifier connected to the phases of the stator rectifies thesinusoidal induced current into a DC current in order to supplyconsumers on the vehicle such as a battery.

On the other hand, in motor mode, the electric machine serves as anelectric motor for rotating, via the shaft of the rotor, the thermalengine of the vehicle. It converts electrical energy into mechanicalenergy. In this case, an inverter converts a DC current coming from thebattery into an alternating current for supplying the phases of thestator in order to rotate the rotor.

Control signals are used to determine the operating mode of the rotaryelectrical machine (motor mode or generator mode).

Finally, it is necessary to supply all the electronic components withpower.

In the document DE 102004007395 A1, the use is known of an externalperipheral band, the said band comprising internal partitions including:

signal interconnection tracks for the transmission/reception of signalsto the electronic components from the bridge rectifier/inverter, and

power interconnection tracks for connecting the electronic components tothe battery so as to supply them, all the tracks being superimposed onone another and being overmoulded. The band is positioned on the rearbearing of the machine. In addition, a dissipator is positioned abovethe said band.

One of the problems of such a solution is that firstly the design of thesuperimposed tracks is complex and may cause short-circuits, andsecondly the cross-sections of power interconnection tracks are toosmall compared with the current necessary, around 150 A in alternatormode and 600 A on starting, for the application of an alternator oralternator starter, so that the said tracks may reach an excessivelyhigh temperature.

SUMMARY OF THE INVENTION

Thus an object of the present invention is to propose an assembly ofelectronic components and power and signal interconnection piecescooperating with the said components in order respectively to distributepower to the said components and convey control signals betweenelectronic components for the functioning of the said machine that caneasily be produced so as to eliminate the risks of short-circuitsbetween tracks and that can withstand the currents passing through thepower tracks.

According to a first object of the invention,

the electronic components are disposed in at least one module disposedon a first plane, the said module comprising a housing defined by a topface and a bottom face and at least three lateral faces,

the signal interconnection piece is disposed on a second plane parallelto the first plane, and

the power interconnection piece is disposed on a third plane parallel tothe first plane,

the power and signal interconnection pieces being independent of eachother and independent of the said electronic modules.

Thus, as will be seen in detail below, having the power interconnectionpiece and the signal interconnection piece on different planes of theelectronic modules it makes it possible to have pieces independent ofthe said modules and to stack the said pieces in a plane different fromthat used by the said electronic components. Thus this avoids theproblems of overmoulding the tracks and therefore of short-circuits. Inaddition, offsetting the interconnections on a different plane of theelectronic modules releases more surface area for the electronic modulesand therefore for the electronic components and also for the power andsignal interconnection tracks. Thus there is a larger cross-section ofpower tracks so as to convey more power. The power and signalinterconnection tracks are thus defined independently of the space takenby electronic components on the machine.

According to non-limitative preferential embodiments, the assembly thatis the object of the invention has the additional characteristics setout below:

the third plane is different from the second plane,

the second and third planes are connected with the first plane byinterconnection elements,

it also comprises a dissipator, integrated or not in a bearing of therotary electrical machine, the said dissipator being on a fourth planeparallel to the other planes.

According to a first assembly mode,

the electronic module comprising electronic components is mounted on thetop face of a dissipator,

the signal interconnection piece is mounted on the top face of thehousing of the said electronic module, and

the power interconnection piece is mounted on the signal interconnectionpiece,

the whole forming an electronic sub-assembly.

The planes of the said modules, of the signal interconnection piece, ofthe power interconnection piece and of the dissipator are superimposedin the following order:

fourth plane,

first plane,

second plane, and

third plane.

The signal interconnection piece comprises electrically conductivesignal tracks, the said tracks comprising signal interconnectionelements, and the second plane is connected to the first plane by thesaid signal interconnection elements, which are intended to cooperatewith signal connections of at least one electronic module.

The power interconnection piece comprises at least one power trackprovided with electrical power terminals, and in that the third plane isconnected to the first plane by the said power terminals, which areintended to cooperate with a power track of at least one electronicmodule.

An electronic module comprises orifices for receiving fixing means forfixing the module (10) to a dissipator.

An electronic module comprises support zones for fixing it to adissipator by pressing.

The signal interconnection piece comprises at least one pre-assemblydevice for fixing the power interconnection piece.

The signal interconnection piece also comprises fixing devices on theelectronic module, disposed on the outside and inside diameters of thesaid piece.

The signal interconnection piece also comprises support devices on anelectronic module, disposed on the outside and inside diameters of thepiece for fixing the said module to a dissipator of the machine bypressing.

The support devices are stays without a sharp edge.

The power interconnection piece comprises fixing devices for fixing toan electronic module, the said devices extending radially on theexternal periphery of the said piece.

The power interconnection piece also comprises pre-assembly devices on asignal interconnection piece.

The power interconnection piece also comprises inserts for receivingfixing means for fixing on the machine.

The power interconnection piece also comprises support devices forsupporting the said piece on a dissipator of the machine.

The power interconnection piece also comprises interleaved andconcentric power tracks.

The power interconnection piece comprises at least one positive powerterminal and at least one negative power terminal for an electronicmodule.

There exists a single positive power terminal and a single negativepower terminal for an electronic module.

The power interconnection piece has a base plate comprising at least onerecess for an electrical connection of a power interconnection trackwith a cover.

A cover is disposed on a fifth plane different from the other planes.

The cover comprises grooves intended to cooperate with guides of anelectronic module.

The cover comprises signal tracks intended to cooperate with signalconnections of an electronic module.

The cover comprises power tracks intended to cooperate with power tracksof the power interconnection piece.

The cover comprises openings for effecting contacts between signaltracks of the cover, power tracks of the cover, and respectively signaltracks of an electronic module, and power tracks of the powerinterconnection piece.

According to a second assembly mode,

the electronic module comprising electronic components is mounted on thetop face of a dissipator,

the signal interconnection piece is mounted above the electronic module,and

the power interconnection piece is mounted on the bottom face of thedissipator,

the whole forming an electronic sub-assembly.

The planes of the said modules, of the signal interconnection piece, ofthe power interconnection piece and of the dissipator are superimposedin the following order:

third plane,

fourth plane,

first plane, and

second plane.

The dissipator is an attached dissipator.

The signal interconnection piece comprises electrically conductivesignal tracks, the said tracks comprising signal interconnectionelements, and the second plane is connected to the first plane by thesaid signal interconnection elements, which are intended to cooperatewith signal connections of at least one electronic module.

The power interconnection piece comprises at least one power trackprovided with electrical power terminals, and the second plane isconnected to the first plane by the said power terminals, which areintended to cooperate with a power track of at least one electronicmodule.

An electronic module comprises an end of a power track configured so asto establish a connection with a fixing terminal of the powerinterconnection piece.

An electronic module comprises a free end of a power track perpendicularto the bottom face of the module.

The power interconnection piece also comprises at least one insert forreceiving a hollow rivet and effecting a pre-assembly with an electronicmodule and a signal interconnection piece and a dissipator.

The power interconnection piece also comprises means of positioning onthe bearing of the rotary electrical machine, the said means extendingover a bottom face of the said piece.

The power interconnection piece also comprises at least one force stayfor an axial deformation of the said piece.

The power interconnection piece also comprises a metal insert so as toeffect an electrical connection with a negative power track.

The power interconnection piece also comprises a collar intended tocover air outlet openings of the bearing of the rotary electricalmachine so as to guide the discharged air and to attenuate any loopingof air.

A cover is disposed on a fifth plane different from the other planes.

According to either one of the two assembly modes, the assembly has theadditional non-limitative characteristics set out below.

An electronic module comprises positioning devices for assembly on thedissipator.

An electronic module comprises power connection ends that are alldisposed in the vicinity of a first face of the housing.

The said ends are all in the vicinity of the outside diameter of therotary electrical machine.

An electronic module also comprises power electronic components thatform at least one bridge rectifier arm, an arm being intended tocooperate with a phase of the stator.

An electronic module also comprises control elements for powerelectronic components.

An electronic module also comprises control electronic components forpower electronic components for the functioning of the rotary electricalmachine.

An electronic module also comprises electronic components intended forthe electrical supply of the excitation winding of the rotor.

The housing of an electronic module is substantially triangular inshape.

An electronic module comprises a face oriented towards the outsidediameter of the machine, which is in the form of an arc of a circle.

An electronic module comprises a power connection that is a phase trackintended to be connected to a phase of the stator of the machine.

The phase track is the only one.

A phase track comprises an end placed between two power electricalconductors.

The bottom face of an electronic module carrying the electroniccomponents and the power connections is fixed to a thermally conductiveplate by means of an electrically insulating adhesive.

An electronic module also comprises signal connection elements that arein the same plane perpendicular to the bottom face of the module, thesaid plane passing essentially through a rotor rotation axis of themachine.

An electronic module also comprises signal connection elements that arealigned on the same lateral face of the housing on which the ends of thepower connections are disposed.

The signal interconnection piece comprises interconnection devices thatare orifices.

The signal interconnection piece comprises a base plate made frominsulating material that overmoulds signal tracks.

The signal interconnection piece comprises interconnection devices, theaxes of which are in a first plane perpendicular to a second plane onwhich all the signal tracks are disposed, the said first plane passingthrough a rotor rotation axis of the machine.

The signal interconnection piece also comprises interconnection devicesdisposed on the external periphery of the said piece.

The signal interconnection piece also comprises metal signal tracksconfigured in the form of arcs of a circle essentially concentric withrespect to a rotation axis of the rotor of the machine.

The signal interconnection piece also comprises positioning studs forassembly on a dissipator of the machine.

The signal interconnection piece also comprises inserts for fixing to adissipator of the machine.

The signal interconnection piece also comprises devices for thepre-positioning of the piece on several electronic modules.

The power interconnection piece also comprises power terminals extendingtowards the external periphery of the said piece.

The said power terminals are not moulded on.

The said power interconnection piece also comprises power terminals withcurved free ends.

The power interconnection piece also comprises a base plate made frominsulating material that overmoulds a power track.

According to a second object of the invention, the invention concerns amethod of assembling electronic components for a rotary electricalmachine and power and signal interconnection pieces cooperating with thesaid components in order respectively to distribute power to the saidcomponents and convey control signals between electronic components forthe functioning of the said machine. In accordance with the convention,the method comprises the steps of:

disposing on a first plane an electronic module comprising theelectronic components, the said module comprising a housing having a topface and a bottom face,

disposing the signal interconnection piece on a second plane parallel tothe first plane,

disposing the power interconnection piece on a third plane parallel tothe first plane,

the power and signal interconnection pieces being independent of eachother and independent of the said electronic modules.

According to non-limitative preferential embodiments, the method that isthe object of the invention has the additional characteristics set outbelow:

The third plane is different from the second plane,

The second and third planes are connected with the first plane byinterconnection elements,

It also comprises an additional step of disposing a dissipator (60)integrated or not in a bearing of the rotary electrical machine on afourth plane parallel to the other planes.

According to a first variant of the method, the said method comprisesthe steps of:

Mounting the electronic module (10) comprising electronic components onthe top face of a dissipator (60),

Mounting the signal interconnection piece (22) on the top face of thehousing of the said electronic module (10), and

Mounting the power interconnection piece (21) on the signalinterconnection piece.

According to a second variant of the method, the said method comprisesthe steps of:

Mounting the electronic module comprising electronic components on thetop face of a dissipator,

Mounting the signal interconnection piece above the electronic module,and

Mounting the power interconnection piece on the bottom face of thedissipator.

According to this second variant, the dissipator is an attacheddissipator.

Moreover, the method comprises an additional step of mounting theelectronic modules plus signal interconnection piece plus dissipatorplus power interconnection piece assembly on a rear bearing of therotary electrical machine.

Other characteristics and advantages of the present invention willemerge from the following description. This is purely illustrative andmust be read with regard to the accompanying drawings, given by way ofnon-limitative examples.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a depicts the first embodiment of an electronic module accordingto the invention,

FIG. 1 b depicts the module of FIG. 1 a in a view from below,

FIG. 1 c is a view without overmoulding of the module of FIG. 1 a,

FIG. 1 d is the view of FIG. 1 c with hard-wired connections of theelectronic components of the electronic module,

FIG. 2 a is a first variant of the first embodiment of FIG. 1 a,

FIG. 2 b is a view from below of the module of FIG. 2 a,

FIG. 2 c is the view of FIG. 2 a with hard-wired connections of theelectronic components of the electronic module,

FIG. 2 d is a second variant of the first embodiment of FIG. 2 a,

FIG. 3 a shows a second embodiment of an electronic module according tothe invention,

FIG. 3 b is a view from below of the module of FIG. 3 a,

FIG. 3 c is a view without overmoulding of the module of FIG. 3 a,

FIG. 3 d is a variant of the second embodiment of FIG. 3 a,

FIG. 3 e is the view of FIG. 3 d with hard-wired connections of theelectronic components of the electronic module,

FIG. 4 a is a third embodiment of the electronic module according to theinvention,

FIG. 4 b is a view from below of the module of FIG. 4 a,

FIG. 4 c is a view without overmoulding of the module of FIG. 4 a,

FIG. 4 d is a view in section without overmoulding of the module of FIG.4 a including a support plate,

FIG. 4 e is the view of FIG. 4 c with hard-wired connections of theelectronic components of the electronic module,

FIG. 5 a is a variant of the third embodiment of FIG. 4 a,

FIG. 5 b is a view from below of the module of FIG. 5 a,

FIG. 5 c is a first view from above without overmoulding of the moduleof FIG. 5 a,

FIG. 5 d is a second view from below without overmoulding of the moduleof FIG. 5 a,

FIG. 5 e is a third view from above without pre-moulding and withoutovermoulding of the module of FIG. 5 a,

FIG. 5 f is a fourth view from below without pre-moulding and withoutovermoulding of the module of FIG. 5 b,

FIG. 6 depicts a first embodiment of a dissipator bearing intended toreceive a module of FIGS. 1 and 2,

FIG. 7 depicts a second embodiment of a dissipator bearing intended toreceive a module of FIG. 3,

FIG. 8 a depicts a first embodiment of a dissipator intended to receivea module of FIGS. 4 and 5,

FIG. 8 b is a view from below of the dissipator of FIG. 8 a,

FIG. 8 c is a view in section of FIG. 8 b,

FIG. 8 d shows an axial air flow and a radial air flow in the dissipatorof FIG. 8 b,

FIG. 9 a depicts a first embodiment of a signal interconnection pieceintended to be placed on a module of FIGS. 1 and 2,

FIG. 9 b is a view from below of the piece of FIG. 9 a,

FIG. 9 c is a view without overmoulding of the piece of FIG. 9 a,

FIG. 10 a depicts a second embodiment of a signal interconnection pieceintended to be placed on a module of FIG. 3,

FIG. 10 b is a view from below of the signal interconnection piece ofFIG. 10 a,

FIG. 10 c is a view without overmoulding of the signal interconnectionpiece of FIG. 10 a,

FIG. 11 a depicts a third embodiment of a signal interconnection pieceintended to be placed on a module of FIGS. 4 and 5,

FIG. 11 b is a view from below of the signal interconnection piece ofFIG. 11 a,

FIG. 11 c is another view from above of the signal interconnection pieceof FIG. 11 a,

FIG. 11 d is a view without overmoulding of the signal interconnectionpiece of FIG. 11 a,

FIG. 12 a shows a first embodiment of a power interconnection pieceintended to be in contact with a module of FIGS. 1 and 2 and to besituated above the signal interconnection piece of FIG. 9,

FIG. 12 b is a view from below of the piece of FIG. 12 a,

FIG. 12 c is a view without overmoulding of the piece of FIG. 12 a,

FIG. 13 a depicts a second embodiment of a power interconnection pieceintended to be in contact with a module of FIG. 3 and to be situatedabove the signal interconnection piece of FIG. 10,

FIG. 13 b is a view from below of the piece of FIG. 13 a,

FIG. 13 c is a view without overmoulding of the piece of FIG. 13 a,

FIG. 14 a shows a third embodiment of a power interconnection pieceintended to receive a dissipator of FIG. 8,

FIG. 14 b is a view from below of the piece of FIG. 14 a,

FIG. 14 c is a view without overmoulding of the piece of FIG. 14 a,

FIG. 14 d is a view of the piece of FIG. 14 a including a collar,

FIG. 14 e is a view of the piece of FIG. 14 d on a dissipator bearing,

FIG. 15 a is a first embodiment of a cover intended to be situated ontop of the power piece of FIG. 12,

FIG. 15 b is a view from above of the cover of FIG. 15 a,

FIG. 15 c is a side view of the cover of FIG. 15 a,

FIG. 16 is a second embodiment of a cover intended to be situated abovethe power piece of FIG. 13,

FIG. 17 a is a third embodiment of a cover intended to be situated ontop of the signal interconnection piece of FIG. 11,

FIG. 17 b is a view from above of the cover of FIG. 17 a,

FIG. 18 depicts a mounting of an electronic module of FIGS. 1 and 2 on adissipator bearing,

FIG. 19 depicts a mounting of a signal interconnection piece of FIG. 9on the dissipator bearing/modules assembly of FIG. 18,

FIG. 20 depicts a mounting of the power interconnection part of FIG. 12on the dissipator bearing/module/signal interconnection piece assemblyof FIG. 19,

FIG. 21 depicts the arrangement of FIG. 20 with a cover in partialcross-section,

FIG. 22 is a complete view of the arrangement according to FIG. 21 withthe cover in place, showing a positioning of the cover with respect to amodule,

FIG. 23 depicts a mounting of an electronic module of FIG. 3 on adissipator bearing,

FIG. 24 depicts a mounting of the signal interconnection part of FIG. 10on the dissipator bearing/modules assembly of FIG. 23,

FIG. 25 depicts a mounting of the power interconnection part of FIG. 12on the dissipator bearing/module/signal interconnection piece assemblyof FIG. 24,

FIG. 26 depicts the arrangement of FIG. 25 with a cover in partialcross-section,

FIG. 27 a depicts a mounting of the modules of FIG. 4 on a dissipator,

FIG. 27 b depicts a mounting of the power interconnection piece of FIG.14 on a dissipator,

FIG. 28 depicts a mounting of the power interconnection piece of FIG. 14on the dissipator/modules assembly of FIG. 27 a,

FIG. 29 depicts a mounting of the signal interconnection piece on theassembly of FIG. 28,

FIG. 30 a is an assembling of the assembly of FIG. 29 on a bearing,

FIG. 30 b is a section along a plane X-Y of FIG. 30 a of the assembledpower interconnection piece of FIG. 14 a, and

FIG. 30 c depicts a bearing on which the assembly of FIG. 29 isassembled.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

It should be noted that, in the remainder of the description, thediameter of a bearing of the machine without fixing lug is defined asthe outside diameter of the machine.

Electronic Module

It should be noted that an electronic module, in the context of theinvention, is a set of electronic components that are disposed in ahousing and comprises connection elements accessible from the outsidefor its functioning, these elements making it possible to transmitcontrol and/or power signals.

FIG. 1 a depicts a first non-limitative embodiment of an electronicmodule 10 according to the invention.

The said module 10 comprises:

a housing 101,

electronic components 102 located in a central zone 1021 covered with aprotective gel such as a gel of the silicone or epoxy resin type, and aprotective plastic cover,

electrical conductors 103 (B+), 104 (B−),

signal connection elements 106, and

fixing points 108.

In addition, the said module 10 comprises, as indicated on the view frombelow in FIG. 1 b:

means 109 of positioning the module 10 on a dissipator bearing.

The various elements of the said module 10 are described below.

-   -   The housing 101 is made from electrically insulating material.        Preferably, the housing has a substantially triangular basic        shape and therefore has at least three lateral faces and one top        face and one bottom face. This shape will make it possible to        use a maximum amount of surface area on the cylindrical rear of        the machine, and this in an optimum fashion.

Moreover, preferentially, one of the faces of the module 10 is an arc ofa circle. This is appropriate to the general shape of the machine.

Naturally it would be possible to use other shapes, such as asubstantially rectangular shape.

-   -   The electrical power supply conductors 103 (B+), 104 (B−) convey        a current coming from the battery through the electronic        elements.

In a preferential embodiment, the conductors are two power connectiontracks 103, 104, the ends of which are disposed on the externalperiphery of the module. Preferentially, the said tracks are made fromcopper.

Thus, unlike an architecture in which the power necessary for eachmodule passes through all the modules or in which an electronic powercard is situated in a housing separate from the machine, thisconfiguration has the following advantages:

this allows a salt spray to flow towards the outside of the machineinstead of banking up at the centre of the said machine, which preventscorrosion of the tracks by the said salt spray,

there is less heating in the modules since the power necessary for amodule passes only through the said module,

the welds on the ends of the tracks are carried out on a single radius,which makes it possible to automate the welding better,

this also allows balancing of the current in the modules because eachmodule is supplied independently, i.e. they are supplied in parallel.

In a first variant of this embodiment, the power tracks 103, 104 extendin a plane parallel to that along which the block of electronic elementsextends. This allows laser welding axial with respect to the axis of themachine.

In a second variant, the tracks extend along two planes parallel to eachother and parallel to the plane of the block of electronic elements.

It should be noted that track means a cropped metal sheet formed from ametal such as copper.

-   -   The signal connection elements 106, called signal connections,        convey control signals for controlling the electronic elements        102. They thus allow the sending and reception of information        necessary for controlling the inverter arm (motor mode) and/or        the arm of the bridge rectifier (generator mode). They afford        connection with a signal plate (described below).

In a first preferential embodiment, these signal connections 106comprise a first series of tongues 106 a and are aligned on one of thelateral faces of the triangular housing of the module. Thus the axes ofthese signal connection elements 106 a are in the same plane P1perpendicular to the bottom face of the module, the said plane passingessentially through the rotor rotation axis AX.

This alignment makes it possible to carry out linear tongue welding,which limits the time needed for the manufacturing method, called the“process”, and the size. This configuration has the advantage of having,for the signal interconnection piece, a signal track cut in one go,unlike another configuration in which the signal tracks overlap. It willbe noted that, if the tongues are offset towards the inside of themodule, i.e. if the plane does not pass through the rotation axis, thespace for the electronic components 102 is reduced, and otherwise thespace for the other modules is reduced.

-   -   Fixing means 108, represented here by orifices, are intended to        facilitate the holding of the module on the electrical machine        by means of studs 113 or screws etc, or any appropriate fixing        means.    -   The means 109 of positioning the module 10 on a dissipator        bearing or dissipator are here two in number 109 a, 109 b as        illustrated in FIG. 1 b, which are on the bottom face of the        module, close to two opposite edges. In the example, these are        pins situated on each side of the electronic elements 102. They        are here spaced at a maximum, which limits positioning errors.

In addition, preferentially, the module 10 also comprises, asillustrated in FIG. 2 a:

Means 107 of protecting the signal connections 106, facilitating thepositioning of a cover (described below).

In addition, preferentially, the said electronic module 10 alsocomprises, as illustrated in FIG. 1 a:

A phase track 105 connecting the said module to a phase of the stator.

In a preferential embodiment, the phase track 105 has an end 105 z thatcomprises a hook 105 cr and makes it possible to connect thereto, bywelding, brazing or any other suitable method, a phase wire or phasetongue coming from the stator of the electrical machine. In the exampledepicted in FIG. 1 a, the said end 105 z is perpendicular to the saidtrack, i.e. to the bottom face, and is situated below the said plane; itextends downwards. Thus this allows a reduction in the length of thephase wire of the stator and involves a radial weld. In addition, theend 105 z of the phase track 105 is situated on the externalcircumference of the module, which facilitates the connection with aphase of the stator. In addition, preferentially, the end 105 z of thephase track 105 is placed between two electrical power conductors 103,104.

This optimises the “wire bounding” hard-wired electrical connectionsbetween the transistor electronic components and the tracks, inparticular their length, and this makes it possible to avoid overlappingof tracks. In addition, preferentially, the end of the phase track 105is situated in line with a phase output of the stator, which facilitatesthe welding with the said phase.

In addition, preferentially, according to a first variant of thisembodiment, the said electronic module 10 is a control module 30 thatalso comprises, as illustrated in FIGS. 2 a and 2 b:

A third series of signal tongues 106 c that are aligned on the externalperiphery of the triangular housing of the module, the said peripherycoinciding with the outside diameter of the machine. This series oftongues makes it possible to be connected to a signal connectorintegrated in a cover.

A second series of tongues 106 b that are aligned parallel to the thirdseries 106 c and offset towards the inside of the module. This secondseries of tongues conveys complementary signals that have not been ableto be integrated in the first series of tongues 106 a, for examplesignals SC for a control element of a switch. This enables the twoseries of tongues 106 b and 106 c to be cropped on a single occasion. Itshould be noted that the third series of tongues 106 c is preferentiallypositioned higher than the second series 106 b in order to facilitatethe welding of a cover to the control module after having carried outthe welding of a signal interconnection piece.

In other words, the second and third series of signal connections 106 b,106 c are aligned on the same face on which the ends of the powerconnections are disposed.

a housing 112 for stator position sensors.

It should be noted that the interconnections between the transistors andthe associated tracks are effected by “wire bounding” hard-wiredconnections as illustrated in FIG. 2 c. In the context of a module witha single transistor per potential, there is one transistor disposed onthe positive track 103, which is connected to the phase track 105 and tothe ceramic 1110 of the driver 111, while a second transistor isdisposed on the phase track 105 and is connected to the negative track104 and also to the ceramic 1110. It should be noted that it would alsobe possible to have a transistor on the negative track 104.

It should be noted that, in this example, there are four transistors,two transistors for the “low side”, indicated LS, and “high side”,indicated HS, of an arm, that is to say two transistors per potential inorder to increase the power of the machine.

In addition, preferentially, according to a second variant of thisembodiment, the said electronic module 10 is an excitation module 40, asillustrated in FIG. 2 d. It comprises electronic components 102, inparticular MOS transistors and diodes, which represent the excitationstage of the rotor of the machine.

Thus the electronic modules 10 have, with regard to the arrangement ofthe tracks 103, 104 and their ends forming electrical conductors insideeach module and with regard to the arrangement of the signal connections106, a standardised architecture makes it possible to use the saidmodules on different types of electrical machine. This standardisationof the architecture makes it possible to replace any module 10 with amodule with the same architecture. In addition, this makes it possibleto integrate the said modules directly on the rear bearing of themachine. In this way the power and control electronics are integrated onthe machine directly. The electronics are no longer in an electronicpower card in a separate housing.

Thus, according to the architecture of an electronic module 10 describedpreviously, it is possible to have power modules 20 (FIGS. 1 a to 1 c),a control module 30 (FIGS. 2 a to 2 c) and an excitation module 40 (FIG.2 d).

In the case of the power modules 20, the electronic components 102,illustrated in FIG. 1 c, comprise for example:

a set of electronic switches 110 intended to produce a rectifierbridge/inverter arm for a phase of the machine,

control elements 111, called drivers, associated with the switches, and

a temperature sensor 118 (positioned on a ceramic) for the phase track105.

The switches can for example be MOSFET-technology transistors 110 thatare in the form of packaged components, that is to say presented with acan, or, in order to increase the compactness of the arrangement of themodules and to reduce costs, in the form of bare chips, that is to saywithout a can. The MOSFETs 110 are controlled by the control elements111, normally called drivers, on a ceramic 1110 with additionalcomponents. Preferentially, the drivers are ASICs. The electronicelements can also be diodes of an arm of a bridge rectifier, since MOSshave a better efficiency than diodes. The number of electroniccomponents depends essentially on the constraints of the particularapplication (three-phase or hexaphase machine for example), the level ofpower required by the machine, etc.

For a three-phase machine, there will preferably be three power modulesserving to produce an inverter (one module per phase). More generally,the machine is a polyphase machine (x phases), preferably having onemodule per phase.

FIG. 1 d illustrates the hard-wired connections, normally referred to as“wire bounding”, between the transistors and the power connections 104and the phase connections 105. It should be noted that, in this example,there exist four MOS transistors, so as to increase the power of themachine. Naturally there may be only two of them. It should be notedthat the ceramic 1110 also serves as a support for electronic componentsbut also as interconnection between the transistors and the driver 111.

The control module 30 makes it possible to control the machine and inparticular the adjustment of the excitation current by controlling thedrivers of the MOS transistors. It also has, as illustrated in FIG. 2 a,an electronic control component 102CTRL, capacitors 102CA and atransformer 102TR for supplying the drivers 111 of the power modules.Control signals will thus be sent from the control component 102CTRL tothe drivers 111 of the power modules.

The excitation module 40 makes it possible to supply the coil of therotor of the said machine, the said module comprising in a conventionalmanner MOS transistors and diodes for determining the current in therotor.

Thus the control module 30 and the excitation module 40 repeat thearchitecture of the power modules 10 and in particular the arrangementof the ends of the power tracks 103, 104 and the signal connections 106.

According to a variant embodiment, the control module 30 and theexcitation module 40 can be replaced by a common excitation and controlmodule.

All the modules 20, 30 and 40 are mounted on a rear bearing of therotary electrical machine.

In a second non-limitative embodiment, illustrated in FIG. 3 a, theelectronic module 10 differs from the first embodiment in that:

in place of the fixing means 108, it has support zones 114 for receivingstays belonging to a signal interconnection piece, as will be describedbelow, which makes it possible to omit the fixing studs 113 so that thecost of the parts and assembly are reduced, and this makes it possibleto obtain a simpler assembly.

The novel module 10 can be seen in view from below in FIG. 3 b and in aview without overmoulding in FIG. 3 c for a power module. It shouldsimply be noted in FIG. 3 b that the module preferably comprises afixing clip 125 for a plastic cover for a module in order to protect theprotective gel for the components. This fixing clip can be replaced by abonding of the cover or ultrasonic welding for example.

FIG. 3 d presents a variant embodiment for a control/excitation module30/40. It should be noted that having a single module for the controland excitation function makes it possible to save in terms of size.

FIG. 3 e presents the “wire bounding” hard-wired connections of thisvariant. It should be noted that there exists an interconnection betweenthe control ceramic and the excitation ceramic (substrate) produced by a“wire bounding” hard-wired connection to allow transmission of signalsbetween the excitation part and the control part.

In the first two embodiments described, preferentially, the ends of thesaid power tracks 103, 104 are flat and flush on the bottom face of thesaid module. Thus this configuration has the advantage of being able toweld tracks of a power plate (described in detail below) on the ends oftracks of a module by transparency (flat on flat).

In a third non-limitative embodiment, illustrated in FIG. 4 a, theelectronic module 10 is configured so as to be fixed to a dissipator,itself fixed to the rear bearing of the machine.

It differs from the second embodiment in that:

the end 105 z of the phase track 105 is perpendicular to the bottom faceof the module and projects beyond the housing 101 of the module and itsplastic cover, and extends upwards. Thus this allows axial welding andthus prevents being interfered with by the lugs fixing the alternatorstarter on the engine, whatever the engine of a manufacturer; and thisfacilitates access to the welding tool,

the end of the positive track 103 (B+) is a folded tongue allowingradial laser welding with a power plate or axial electric welding byelectrodes; it extends axially upwards with respect to the housing 101of the module and projects beyond the said housing in order to engagethe said electrodes, i.e. it is perpendicular to the bottom face of themodule; the tongue projects beyond the dissipator. This makes itpossible to connect a power interconnection piece 21 with the modulefrom below,

the end of the negative track 104 (B−) is no longer a tongue but ahollow cylindrical metal insert allowing electrical connection to adissipator 80 via the track B− and a screw 1150 corresponding to theorifice 115, the said screw making it possible to compress the saidtrack on the insert and thus to compress the track plus insert on thedissipator so as to effect the earthing of the module, the saiddissipator being earthed as will be described in detail below,

the positioning pins 109 situated on the bottom face are positioneddifferently. A first pin 109 a is positioned as close as possible to thesignal tongues 106, and preferentially centred on the middle one, inorder to reduce the positioning tolerance of the said tongues withrespect to any clearance that may exist between the second pin 109 b andthe corresponding orifice 609 b (described in more detail below) of thedissipator bearing. In this way the positioning errors of the tongueswith respect to the dissipator are reduced. As illustrated in FIG. 4 b,this first pin 109 a is situated at the middle of the two end signaltongues 106 a. It should be noted that the first pin 109 a serves toposition the module along the axis X-Y, and the second 109 b serves toorient the module in terms of rotation and is the furthest away from thetongues 106 a,

one of the protective pins 107 is placed more towards the outside of themodule so that there exists a kind of support 119 to make it possible toreceive a stay of a signal plate. The pins 107 prevent the signaltongues 106 bending between the time of the manufacture of the moduleand its assembly on the machine, and serve as preliminary guidance for asignal interconnection piece (described below).

In addition, the module 10 according to this third embodiment alsocomprises:

an insert 120 comprising a fixing orifice 115, the said insert allowingearthing of the module, and the said orifice being intended to fix thesaid module to a dissipator by means of screws 1150 for example,

means 126 of electrical protection of the end of the track 103 (B+) thatprevent a short-circuit between the potentials B+ (power track of thepower interconnection piece) and B− (dissipator mass).

A view without overmoulding of a power module 20 according to this thirdembodiment is shown in FIG. 4 c.

A view with the “wire bounding” hard-wired connections is shown in FIG.4 e.

Preferentially, each power module 20 comprises a plate 1022 of lowresistance and low thermal conductivity, preferentially made fromaluminium (the same resistance as the dissipator) or copper.

Thus there are:

the electronic components 102 welded to the metal tracks,

the metal tracks, which are visible on the bottom face of the housing ofthe module, are bonded to the plate 1022 by an electrically insulatingand thermally conductive adhesive, for example a glass-ball adhesive,the said adhesive electrically insulating the tracks from each other andthe tracks with respect to the outside, and

the plate 1022, which is placed on the dissipator.

The plate 1022 is illustrated in FIG. 4 d (representation incross-section along an axis A-A in FIG. 4 c). It should be noted thatthis plate can be used in the same way on the other control orexcitation modules in the context of visible tracks.

The plate thus makes it possible to test the electrical insulation ofeach module independently before assembly on the dissipator ordissipator bearing. Thus, if there exists a problem of short-circuit dueto faulty application of the insulating adhesive, this plate 1022 avoidsthe scrapping of all the modules mounted on the dissipator. Only themodule posing a problem will be disposed of before it is assembled onthe dissipator.

According to a variant of this third embodiment, the module 10comprises, as illustrated in FIG. 5 a:

a signal connector 116,

a screw 117 a affording electrical contact between two tracks 117 b(+EX, −EX) of a brush holder 50 and the said module 10, and

a screw 117 c for mechanical holding on the dissipator and making itpossible to withstand the mechanical forces of the connector 116.

More particularly it is the control module 30 or the control/excitationmodule that comprises the said connector 116 and the said screw 117 a.It should be noted that the brush holder is here in a single piece withthe said module 30. Indeed it is moulded on with the said module.

The presence of the said signal connector 116 has the advantage of:

eliminating welds making it possible to effect electrical connectionsbetween the cover and the modules, compared with the first embodiment,

avoiding problems of welding and impermeability,

saving time in the manufacturing process.

There therefore no longer exist any external tongues 106 c as in thefirst or second embodiments, which makes it possible to reduce thematerial of the tracks (those in the cover) as will be seensubsequently.

FIG. 5 b is a view from below of the control module 30 according to thisthird embodiment.

As can be seen, the first positioning pin 109 a is as close as possibleto the two series of signal tongues 106 a and 106 b in order to limitany errors in positioning of the tongues with respect to the dissipator.

In addition there can also be seen:

a metal plate 121 fixed by the screw 1150, the said plate preferentiallybeing made from aluminium and thus being connected to the dissipatormass via the said screw 1150, the said plate comprising substrates 123of the ceramic type, on which electronic components are integrated,

position sensors 122 for giving the position of the stator of theelectrical machine.

FIG. 5 c is a view from above of the control/excitation module withoutovermoulding, without the connector 116 and without the brush holder 50.FIG. 5 d shows the view from below.

FIG. 5 e is a first view without pre-moulding and without overmouldingof the tracks of the control/excitation module in which there can inparticular be seen:

a control ceramic 123 comprising the electronic components forcontrolling the machine, and

an excitation part 124 comprising the electronic components forexcitation of the machine via the brush holder 50.

The tracks of the said module can also be seen in the following FIG. 5 fwithout pre-moulding and without the plastic overmoulding in a view frombelow.

It should be noted that the pre-moulding is an operation that takesplace before the overmoulding and that makes it possible to hold certainelements in position, such as the signal tongues 106 for example.

It should be noted that, in all the embodiments, the electroniccomponents 102, in particular the MOS transistors, are mounted on thepower connections, namely here the positive track 103 and the phasetrack 105.

Preferentially, in all the embodiments presented above, the power tracksof the modules are visible on the bottom face of the modules. It is thuspossible to isolate them electrically from the dissipator or dissipatorbearing by means of adhesive in place of the plastic of the housing 101.The use of adhesive in place of the plastic of the housing 101 makes itpossible to have a lesser thickness under the modules (approximately 0.2mm in a non-limitative example) and to have a lower thermal resistancethan plastic so as to have better dissipation in the dissipator bearingor dissipator.

It should be noted that, in all the embodiments presented above, it isof course possible to include or not the signal connector 116 in thecontrol module or control/excitation module if so desired. If it is notincluded, it will be in the cover.

It should be noted that the electronic module according to all theembodiments presented above has the following additional advantages:

it uses bare chips for the electronic components instead of so-calledpackaged standard components, so as to reduce the size,

it includes the elements for controlling the MOS transistors, referredto as drivers,

a module is configured in order to be perfectly integrated on thedissipator or dissipator bearing so that:

-   -   it does not block the axis of the bearing in which the shaft of        the rotor is introduced,    -   there exists an axial cooling with the attached dissipator (not        integrated),    -   all the ends of the power and signal tracks are outside the        circumference of the dissipator or dissipator bearing, which        facilitates the connections to be established, unlike the case        where they are inside the said circumference, so as to be        accessible and so that there exists more space available on the        outside diameter than inside for the said ends,

a module is preferentially configured for a single phase so that:

-   -   the hook of the module is opposite the natural exit of a stator        phase,    -   there is one module per phase. Thus adaptation to the space        available on the dissipator or dissipator bearing is easier        compared with a single module comprising three phase tracks, and        this in an optimum manner.

the definition of the module makes it possible to have a power, controland excitation module with the same architecture,

in the event of failure of welding of one of the transistors, it avoidstoo much scrap compared with a single module for the three phases of thestator.

It should be noted that it is also possible to provide a singleovermoulding for all the power modules 20, the control module 30 and theexcitation module 40 or control/excitation module 30/40.

At this moment there would be a single module that would comprise thepower, the control and the excitation, the said module then comprisingthree phase tracks.

Other Elements

An electronic module 10 cooperates with the following elements:

a dissipator bearing 60 (dissipator integrated in the bearing, i.e. in asingle piece with the said bearing), or a dissipator 80 (dissipator notintegrated in the bearing, i.e. attached to the bearing)

a signal interconnection piece 22

a power interconnection piece 21, and

a cover 70.

These elements are described below.

Dissipator Bearing

The function of a dissipator bearing is to discharge the heat from theelectronic modules.

The rear dissipator bearing 60, shown in FIG. 6, comprises, according toa first non-limitative embodiment:

a plurality of positioning orifices 609, preferentially two 609 a, 609 bper module, in order to position the said modules on the said bearing,the said orifices being situated on the same diameter, i.e. in theexample illustrated ten orifices,

a plurality of fixing orifices 608 for receiving the three fixing studsof each module on which the power plate will be positioned, that is tosay in the example illustrated fifteen orifices,

air inlets 601 comprising fins 606,

air outlets 602 comprising fins 606,

various recesses referenced 603 for the rotor shaft of the rotaryelectrical machine, 604 for the Hall effect sensors making it possibleto know the rotor position, and 605 for a brush holder 50, and

positioning orifices 610 for positioning a signal plate, here twoorifices 610 a and 610 b that are distributed on each side of thediameter of the dissipator bearing. Preferentially one of the orificesis the reference control for the dissipator bearing, and thus an alreadyexisting orifice is used.

It should be noted that FIG. 6 shows the locations of the variousmodules. Thus the locations marked P, c and E receive respectively thethree power modules 20, the control module 30 and finally the excitationmodule 40.

According to a second non-limitative preferential embodiment illustratedin FIG. 7, the dissipator bearing 60 comprises:

a plurality of fixing orifices, here four, 681, 682, 683 and 684 forreceiving four studs holding the signal plate,

a fixing orifice 685 for receiving a fixing screw of a brush holder 50,there is no stud, which avoids reducing the cross-section of the trackB+ of a power plate,

the following same elements as the first embodiment:

-   -   air inlets 601 comprising fins 66,    -   air outlets 602 comprising fins 606,    -   various recesses 603, 604 and 605, and    -   the positioning orifices 610 a and 610 b for the signal plate.

It will be noted that the control and excitation functions have beencombined in a single control/excitation module. Moreover, the locationC/E and P respectively of the control/excitation module and the powermodule 20 in FIG. 7 will be noted.

It will also be noted that the fins 606 can, as known to persons skilledin the art, be replaced by a liquid cooling circuit for the twoembodiments of the dissipator bearing described above.

Dissipator

The function of the dissipator is to discharge the heat from theelectronic modules.

The dissipator 80 as illustrated in plan view in FIG. 8 a is independentof the rear bearing of the rotary machine.

It comprises, according to a non-limitative preferential embodiment:

a base plate 801 preferentially made from cast aluminium, and

fixing orifices 806 on the rear bearing of the machine, here four, inorder to receive fixing studs of a signal plate,

an electrical connection orifice 805 for connecting the dissipator toearth via the power interconnection plate by means of a nut,

fixing orifices 804 for fixing the modules, here four, and connectingthem to the dissipator earth via an insert,

a fixing orifice 807 for fixing a signal connector of thecontrol/excitation module via an insert,

mechanical positioning orifices 808 for positioning a power plate 21,here two distributed on each side of the diameter of the dissipator,

recesses 809 on the circumference for receiving electrical protectionmeans, here three, for the positive track (B+) of the powerinterconnection piece,

positioning orifices 810 for the modules, here two per module, that isto say eight orifices,

mechanical positioning orifices 811 for positioning a signal plate 22,here two distributed on each side of the diameter of the dissipator, and

recesses 812 for inserting phase housings of a power plate as will beseen in detail below. There therefore exist three of them here,

recesses 815, 816, 817 for receiving respectively a brush holder,position sensors and the rotor shaft.

The locations C/E and P respectively of the control/excitation moduleand the power modules 20 will be noted.

FIG. 8 b shows a plan view of the dissipator.

It can be seen that the dissipator also comprises:

blocks of cooling fins 802 intended to substantially increase the heatdissipation of the power modules 20, the said blocks being situated onthe bottom face in the position of use of the base plate 801,

support zones 814 for receiving force stays for the powerinterconnection piece that make it possible to withstand the enginevibrations,

a protrusion 813 that guides the air from the radial inlet of themachine towards the inside of the said machine and thus prevents the airstagnating at the dissipator. This is also the case for the axial air.It is guided towards the inside of the machine. It should be noted thatthe fins at this level pass through the said protrusion 813. A sectionX-X of the protrusion can be seen in FIG. 8 c.

In addition, it should be noted that the base plate 801 is configuredfirstly so as to be able to be assembled in a sandwich between a powerinterconnection plate and the modules, and a signal interconnectionplate, and secondly to leave at the centre a sufficiently large passagefor the cooling air of the electrical machine.

As indicated in FIG. 8 d, a first flow of the air will enter the machinein this way axially FA. This has the advantage of increasing the speedof the air and thus reducing the pressure drops compared with a radialflow (the case of the first and second embodiments of the dissipatorbearing described previously).

In this way, a looping of air heated by the machine between an outputand an input of the dissipator bearing is avoided (for the air incomingaxially) and thus re-injecting hot air into the machine is avoided.

More particularly, it is the spacing 817 that is configured so as toallow air to pass around the rotor shaft and is therefore wider than thediameter of the rotor shaft or, to be more precise, of the shaftcollector protector.

In this way the standard cooling applied to a conventional alternator isapproached.

Moreover, the axial air flow is guided by the first slope 813P1 of theprotrusion 813 of the dissipator so that there is no stagnant air on thebottom face of the dissipator level with the fins.

In addition, by virtue of the positioning of the dissipator described,there is also a second air flow that is radial between the dissipator 80and the power interconnection piece 21. This can also be seen in FIG. 8d. This radial air FR enters through the dissipator and leaves againthrough the openings 606 in the bearing. This radial air flow increasesthe output of air and therefore improves the cooling of the machine, thelatter thus being more efficient than if there were only an axial airflow.

In addition, by virtue of the protrusion 813 situated level with thefins, this radial air flow does not stagnate since it is guided by thesecond slope 813P2 of the said protrusion 813 towards the inside of themachine.

It should be noted that these radial FR and axial FA air flows areaccelerated by the fan of the machine, which gives rise to a bettercooling of the machine plus the electronics because in particular of thearrangement of the dissipator as described above.

Signal Interconnection Plate

The signal interconnection plate 22 is intended to convey varioussignals necessary for the functioning of the modules and, thereby, forthe correct functioning of the rotary electrical machine. Such signalsare for example:

a signal for the operating mode of the electrical machine, for examplemotor or generator.

a signal indicating the temperature of the modules,

a signal sending back a fault detected on the modules,

a control signal for the switches of the MOSs etc.

These signals are conveyed between the power modules 20 and the controlmodule 30.

FIGS. 9 a to 9 c show a first non-limitative embodiment of the signalinterconnection piece 22.

It comprises:

a base plate 220 made from insulating material, preferentially made fromplastic, and preferentially substantially cylindrical, which moulds onmetal signal tracks TS,

a central recess 223 for lightening the said plate in terms of material,

recesses 221 a for leaving visible metal tracks TS, the said trackscomprising interconnection orifices 2210, here five orifices, the axesof which are disposed in a plane P2 (shown in FIG. 9 c) perpendicular tothe surface of the plate and passing substantially through the rotorrotation axis AX, the said orifices being intended to receive the signaltongues 106 of an electronic module with a view to being connectedelectrically,

a connection recess 221 b for leaving visible metal tracks TS, the saidtracks comprising interconnection orifices 2211, disposed at theexternal periphery of the said plate 22, the said orifices beingintended to receive the signal tongues 106 of a control module, herethree orifices, and

fixing lugs 222 intended to be inserted in one of the three holdingstuds 113 of an electronic module, and intended to receive a fixing nut,the said fixing lugs holding the signal interconnection plate 22 on themodules, by means of the studs, first lugs 222 a being disposed on theoutside diameter of the said plate and projecting beyond the said plate,and second lugs 222 b being disposed on the internal diameter of thesaid plate and also attenuating vibrations of the plate.

It should be noted that the recesses 221 a and 221 b can be protectedsubsequently against the external environment by a resin for example.

It should also be noted that the overmoulding 220 comprises orifices2210 z, 2211 z opposite the orifices of the metal tracks TS, asillustrated in FIG. 9 b.

The signal plate 22 also comprises:

positioning pins 224 for assembly on a dissipator bearing 60, here twoas illustrated on the view from below in FIG. 9 b, and

metal signal tracks TS configured to adapt to the shape of the plate andto the position of the tongues 106 of the modules, and comprisinginterconnection orifices 2210, 2211 as illustrated in FIG. 9 c. The saidtracks are preferentially in the same plane. Moreover, they arepreferentially configured in the form of arcs of a circle essentiallyconcentric with respect to the rotor rotation axis.

FIGS. 10 a to 10 c depict a second preferential embodiment of the signalinterconnection piece 22.

This signal interconnection plate 22 comprises:

in place of the fixing lugs of the first mode, stays 225 for pressingthe modules against a dissipator bearing, first stays 225 a and secondstays 225 b being positioned respectively on the external or internalperiphery of the said plate, here nine in total; there are thus threesupport points on each module,

in place of the three recesses per module, only three support inserts226 intended to receive three studs 226 g, for fixing to the dissipatorbearing 60, and

a metal insert 226 for receiving a screw 226 v for fixing the plate tothe dissipator bearing. This screw avoids reducing the cross-section ofthe positive power tracks (B+) of the power interconnection piece 21(described below).

These four inserts also prevent flow of the overmoulding plastic. Itwill therefore also be possible to use them for the first embodiment.

The plate 22 also comprises:

at least one fixing housing 227 for fixing the power interconnectionpiece 21 and receiving a fixing clip (218), here two housings, and

an additional central recess 228 for receiving a brush holder.

In a first variant embodiment of this mode, the plate also comprisesseparators 229 for signal tongues 106 so as to prevent short-circuitsbetween the said tongues, short-circuits due in particular to saltspray. In this way the length of the electrical path between the tonguesis increased.

In another variant, the said plate does not have any separators. At thismoment, in order to isolate the said tongues from each other, seals areprovides that surround the said tongues 106 on the modules themselves.Subsequently the signal plate 22 will compress these seals.

It should be noted that these two variants apply to the two embodimentsof the electronic module described above and to the third embodiment,which will be described later.

In FIG. 10 c, it is possible to see the concentric metal tracks of thesignal plate 22. The said metal tracks are configured to adapt to theposition of the tongues 106 of the modules, and preferentially to theshape of the said plate, and in addition to pass round the four inserts226. They are preferentially configured in the form of arcs of a circleessentially concentric with respect to the rotor rotation axis.

It should be noted that the stays 225 are, non-limitatively, cylindricalin shape. This shape has a sharp edge 2250.

In addition, it should be noted that the interconnection plate 22according to this second embodiment has the following same elements asthe plate according to the first mode:

the base plate 220,

the recesses 221 a and 221 b,

the central recess 223 intended to receive here a rotor shaft,

the positioning pins 224, and

the metal tracks TS with the orifices 2210 and 2211.

It should be noted that, for the first and second embodiments describedabove, the signal tracks are preferentially configured inside thediameter on which the power terminals (described in detail below) areproduced. This enables the power plate 21 (described below) to fit ontop of the signal plate 22. Thus assembly is facilitated and the saidsignal tracks do not interfere with the power tracks.

FIGS. 11 a to 11 d depict a third non-limitative embodiment of thesignal interconnection piece 22.

It differs from the second embodiment in that:

it no longer has any fixing housings 227 for positioning the powerinterconnection piece 21 since in this embodiment the power plate 21 issituated below the signal plate 22, as will be seen in detail below.

the stays 225 a and 225 b have a different shape. They have a shape thatno longer comprises any sharp edge, which prevents the stressesundergone by the plastic being concentrated on the sharp edges. In thisway the risk of breaking the said stays is reduced.

The said signal plate 32 also comprises:

hollowed-out protuberances 230 for pre-positioning the said plate on thesaid modules. Here there exist two protuberances. They serve inparticular for pre-guidance during the process assembly. This thus makesit possible to subsequently fix the positioning pins 224 of the saidplate 22 in the dissipator 80. It will thus be possible to position thesignal plate 22 before the assembly of the signal tongues 106, and

housings 231 for housing therein filtering capacitors. These capacitorswill be connected to the electronic modules. The housings afford goodmechanical strength for the said capacitors. Resin will be deposited inthe said housings.

Moreover, it should be noted that the interconnection plate 22 accordingto this third embodiment has the following same elements as the plateaccording to the second embodiment:

the base plate 220,

the recesses 221 a and 221 b,

the central recess 223,

the recess 228 for the brush holder,

the four inserts 226,

the positioning pins 224, and

the metal tracks TS with the orifices 2210 and 2211.

According to a first variant of this embodiment, the orifices 2210 and2211 are configured so as to effect a tin weld between the said orificesand the corresponding signal tongues 106. These are therefore holes witha bevel as illustrated in FIG. 11 a and in FIG. 11 b in view from below.

According to a second variant of this embodiment, the orifices 2210 and2211 are configured so as to effect a laser weld between the saidorifices and the corresponding signal tongues 106. These are thereforefolded micro-tongues as illustrated in FIG. 11 c.

In FIG. 1 d, the metal tracks of the signal plate 22 can be seen. Thesaid metal tracks are configured so as to adapt to the position of thetongues 106 of the modules, and preferentially to the shape of the saidplate, and in addition to pass round the four inserts 226. They arepreferentially configured in the form of arcs of a circle essentiallyconcentric with respect to the rotor rotation axis.

Thus, unlike an electronic card for fulfilling the signal function, sucha signal plate has the advantages of:

withstanding high temperatures, for example 260° C., unlike aconventional PCB electronic card, such a PCB card being composed ofcopper tracks with a polymer insulator, the said copper tracks notwithstanding high temperatures,

being able to be centred above the electronic modules 10,

comprising metal tracks not necessarily made from copper. This isbecause, having regard to the relatively low power conveyed by thesetracks, a material with a low electrical resistance is not necessarilyrequired. Thus the said tracks can for example, non-limitatively, bemade from steel,

be as close as possible to the modules, which avoids having signaltongues for the excessively long modules and thus avoiding problems ofplugging in,

by virtue of the metal tracks, which do not overlap, a track cutting isachieved in one go, a fine thickness of the plate is obtained, andtherefore a saving in axial size of the whole of the machine, and afacilitated manufacture of the signal interconnection plate.

It should be noted that, naturally, in all the embodiments presentedabove, it is also possible to provide, instead of the interconnectionorifices 2210, 2211, other interconnection means such as folded tonguesfor example.

Power Interconnection Plate

The power interconnection piece 21 makes it possible to distribute thepower between the electronic modules 20, 30, 40 from outside (inparticular the vehicle battery).

This piece is independent of the electronic modules, which makes itpossible to supply each module with current independently and thus avoidthe heating of the modules relating to the passage of the currentintended for one module in all the modules. Thus, according to theconfiguration of this piece and the associated modules, there is no flowof current between the three power modules.

The interconnection piece 21 is, in the most simple case, in the form ofa plate produced from an electrically insulating material, preferablyplastic.

In a first non-limitative embodiment, illustrated in FIGS. 12 a to 12 c,it comprises:

a central recess 210 for lightening the said plate in terms of material,

power interconnection tracks 211 (−BATT), 212 (+BATT),

negative 2110 and positive 2120 power terminals issuing from therespective power tracks 211, 212,

a plastic overmoulding 213 on the said interconnection tracks 211 and212,

a first recess 214 a,

a second recess 214 b, and

fixing lugs 215.

The elements of the power interconnection plate are described in detailbelow.

-   -   The power interconnection tracks 211, 212 are disposed at least        on one face of the plate. These are tracks made from a metal        with low resistance, preferably copper, which are overmoulded in        the plastics material of the power plate 21.

They can be produced in the form of a flat strips clipped, riveted,adhesively bonded or fixed in any other suitable manner to the plasticplate.

According to a preferential embodiment, the tracks 211, 212 areinterleaved (the track 211 is surrounded by the track 212) andconcentric and on the same plane. In this case, the negative powerterminals 2110 are folded so as not to interfere with the positiveinterconnection track 212 (+BATT). In this way, it is possible tooptimise the location of the recesses 214 a, 214 b in order to orient acover according to the requirements of a customer connector making theconnection of the machine with the outside. The said tracks 211 and 212are not superimposed so as to allow electrical connection with thetracks of such a cover, the said zone comprising the recesses 214 a and214 b.

According to a second embodiment, the tracks 211, 212 can besuperimposed on one another. This is beneficial to the radial size.

Finally, it should be noted that each of the power interconnectiontracks 211, 212 comprises a hole 217 a, 217 b making it possible toposition the said track in terms of x, y in a mould, the latter makingit possible to carry out the plastic overmoulding 213.

-   -   The power interconnection tracks 211, 212 have respectively        negative power terminals 2110 (−BATT) in an L shape, and        positive terminals 2120 (+BATT). The said terminals extend        radially towards the external periphery of the said piece 21.        These terminals have curved free ends. The precise dimensions        and position of the terminals 2110, 2120 are determined so as to        enable them to be positioned above the ends of the tracks 104,        103 of each of the modules in order to be able to be connected        to the said tracks by means of welding, brazing or weld-brazing        for example. This configuration of the power terminals (in an L        shape and having ends curved by bending) on the outside diameter        thus facilitates the assembly with the modules. These terminals        thus make it possible to obtain an electrical connection with        the corresponding tracks 103, 104 of the electronic modules 10        so that the electrical power is distributed in each of the said        modules. It will be noted that the positive power track 212        overlaps the negative interconnection terminals 2110.    -   The overmoulding 213 comprises a first recess 214 a for an        electrical connection of the interconnection track 211,        preferably by laser welding, with a cover to the battery, and a        second recess 214 b in the said overmoulding for an electrical        connection of the interconnection track 212, preferably by laser        welding, with a cover to the battery.

Moreover, the overmoulding 213 comprises assembly recesses 216 enablingan assembly tool to pass through the said plate and assemble the reardissipator bearing with a front bearing.

It should be noted that the ends of the power terminals 2110 and 2120are not overmoulded so that the said ends can bear on the ends of thetracks 104, 103 of the modules. Preferentially, the whole of the powerterminal piece is not overmoulded so that assembly on the ends of thetracks is facilitated. This is because this affords more bending in suchan assembly.

-   -   The lugs 215 extend substantially radially over the external        periphery of the interconnection plate. Each of the lugs 215 is        provided with an orifice making it possible to pass therein,        when the various modules and the other elements of the        arrangement are assembled, fixing means such as threaded rods or        bolts or studs or any other suitable fixing element.

In a second non-limitative embodiment, illustrated in FIGS. 13 a to 13c, the power interconnection plate 21 comprises:

a supplementary central recess 2101,

at least one fixing clip 218,

inserts 219 a, 219 b for receiving holding studs,

a mechanical stop 2112,

at least one support pin 2113, and

an orifice 219 c.

The elements of the power interconnection plate are described in detailbelow.

-   -   The supplementary central recess 2101 allows the insertion of        the brush holder with its protector. In this case, the brush        cage protector is an independent piece assembled on the brush        holder, and the brush holder may be removable with respect to        the control/excitation module, which facilitates maintenance of        the machine in particular in a replacement context, that is to        say when the brushes (and therefore the brush holder) are        changed when they are worn. Thus, instead of changing all the        electronics (the modules and the two plates), only the brush        holder will be changed (if the electronics are not faulty).    -   The fixing clips 218 enable the plate 21 to be held mechanically        on the signal plate 22, here three.    -   The inserts 219 a and 219 b for receiving the holding studs,        here two in total, and for connecting the power tracks 211, 212        to a cover 70. The two inserts 219 a, 219 b make it possible to        gain access to the said power tracks so that an overmoulding 213        can be effected on the said tracks as illustrated in FIG. 13 a.        These two inserts thus allow mechanical holding of the plate 1        and an electrical connection.    -   The last orifice 219 c permits solely mechanical holding of the        said plate 21 by means of a stud.    -   The mechanical stop 2112 makes it possible to stop the power        plate 21 in translation when it is assembled. It bears, for        example, on the control/excitation module. In addition this stop        has a shorter length than the power terminals 2110 and 2120 of        the power tracks so that the said terminals bear on the tracks        of the corresponding modules before the stop bears on the        control module. The stop is disposed on the outside diameter of        the plate and projects beyond this plate.    -   The support pins 2113, here two, enable the said plate 21 to        bear on the dissipator bearing during assembly.

The plate 21 comprises, as described in the first embodiment:

the central recess 210,

the power tracks 211, 212,

the negative 2110 and positive 2120 power terminals, and

the overmoulding 213.

It should be noted that the overmoulding 213 comprises here a recess2130 for lightening the plastics material, the said recess beingpossible since no facing power tracks exist. In the same way as in thefirst embodiment, the power terminals 2110 and 2120 are not overmoulded.

The power tracks 211 and 212 are shown in FIG. 13 c.

In addition, according to the first and second embodiments:

the plate 21 can also integrate passive filtering components 2114 shownin FIG. 13 b, for example capacitors connected between the power tracks211 (−BATT), 212 (+BATT) via micro-tongues 21140 a and 21140 b. Thismakes it possible for example to filter the voltage of the on-boardsystem of the motor vehicle and to filter in particular the oscillationsdue to the electrical conversion components, MOSs, diodes, etc,

preferentially, the ends of the power tracks are flat and flush on thesurface of the module. Thus the advantage of this configuration is beingable to weld tracks on a power plate (described in detail below) to theends of the tracks of a module by flat-on-flat transparency,

the power interconnection plate 21 can also integrate a brush cageprotector (not shown) that makes the brush holder impervious. This givesone part less to assemble. The brush holder allows the supply of theexcitation current issuing from the excitation module to the rotor viabrushes. The said protector then comprises positioning guides that willmake it possible to position the said protector opposite the brushholder,

preferentially, the positive terminals 2120 are rigid lugs defining areference support plane for the said power piece on the correspondingtracks of the modules,

preferentially, the negative power terminals 2110 are flexible lugs fortaking into account the assembly tolerances. Thus, when the modules andthe said plate are assembled, this will make it possible to deform thetracks of the said power plate before welding by transparency. This thusfacilitates putting the power interconnection tracks in contact with thecorresponding tracks of the modules. It will be possible to use thisflexibility also for the first embodiment, also for the third embodimentdescribed below (although this is not necessary).

FIGS. 14 a to 14 e show a third non-limitative embodiment of the powerinterconnection piece 21.

The power interconnection plate 21 comprises:

inserts 210 d for establishing a mechanical connection with the rearbearing of the machine,

stator phase protection means 211 d,

means 212 d of positioning on the rear bearing of the machine,

force stays 213 d,

means 214 d of positioning the said plate in the dissipator 80,

a fixing terminal 215 d for fixing the said plate to the dissipator 80,

an electrical insert 216 d,

a power connector 219 d,

positive 221 d (B+) and negative 222 d (B−) tracks moulded on inplastic,

positive power terminals 217 d issuing from the positive track B+,

means 218 d of protecting the positive power terminals 217 d,

a terminal 220 d for mechanical connection to a client power connector(not shown) connected to the battery, and

a mechanical connection orifice 220 e connected to the connectionterminal 220 d.

The elements of the power interconnection plate are described in detailbelow.

-   -   The inserts 210 d for establishing a mechanical connection with        the rear bearing of the machine, by means of screws for example,        here four in total,

the stator phase protection means 211 d are situated on the outsidediameter of the said plate and project beyond the plane of the saidplate, the said means preventing contact between a stator phase and thedissipator mass or bearing mass in particular,

the means 212 d of positioning on the rear bearing of the machine, thesaid means being here a positioning pin, extend on the bottom face ofthe plate, the said pin advantageously being positioned in an oblonghole that is the machining reference orifice of the bearing,

the force stays 213 d allow downward axial deformation of the said powerplate in order to avoid vibration problems, the said stayspreferentially having a greater height than the inserts 210 d in orderto be sure of deforming the plate, the said stays extending over the topface of the plate,

the means 214 d of positioning the said plate in the dissipator 80, heretwo, extend over the top face of the said plate,

the fixing terminal 215 d makes it possible to fix the said plate to thedissipator 80 by means of a nut, and is connected to the negative powertrack B−, which effects an earthing of the dissipator,

the electrical insert 216 d is intended to be assembled with theterminal 215 d on the track 222 d, the said track thus being sandwichedby the said insert and the said terminal, which thus avoids difficultwelding to be performed between the dissipator, which is preferentiallymade from cast aluminium, and the copper power track,

the power connector 219 d comprises a negative track B− and a positivetrack B+,

the power electrical terminals 217 d issuing from a positive track B+are here in an L shape and have an axial tongue, i.e. perpendicular tothe plane of the said plate 21 and projecting beyond the said planeupwards; the said terminals are not overmoulded to allow connection withthe end of the positive track 103 (B+) of an electronic module, theterminals extending towards the external periphery of the said piece 22,

the means 218 d of protecting the electrical terminals 217 d protectagainst short-circuits and salt spray in particular,

the positive 221 d (B+) and negative 222 d (B−) tracks are moulded on inplastic 213 for example, tracks that can be seen in FIG. 14 c. Thetracks are visible on the power connector 219 d, which allows thefitting of the client power connector to make the electrical connectionsbetween the said connector and the said tracks,

the terminal 220 d connecting to the client connector connected to thebattery, the said terminal making it possible to effect a pressingbetween the tracks 221 d and 222 d and the tracks of the client powerconnector so that the current can be established correctly between thebattery and the machine, and

a mechanical connection orifice 220 e for a screw, thus avoiding thetransmission of the mechanical stresses on overmoulding when the clientpower connector is fixed to the connecting terminal 220 d.

Preferentially, in a variant embodiment, as depicted in FIG. 14 e, theovermoulding 213 of the power plate 21 covers the air outlet openings ofthe bearing (as far as the outside diameter of the bearing) so as toguide the discharged air in order to reduce a radial looping back of theair towards the inside of the machine. Thus the said overmouldingcomprises a covering collar 213 z shown in FIG. 14 e.

Thus the power plate has the advantages of:

having a single track without overlap, the said track making it possibleto effect easier moulding and positioning,

being fixed under the dissipator 80 and therefore being separated by amass from the signal interconnection plate 22, so that the power signalB+does not interfere with the signals from the said signalinterconnection plate 22,

a saving in axial size since the power plate 21 is positioned in thespace necessary for the fins of the dissipator,

enabling the dissipator to be an isolated mass (with respect to that ofthe bearing) or not, and therefore a different mass from that of thebearing, thus avoiding interference of the on-board system duringstarting in particular.

It will be noted that, by virtue of the presence of the power plate 21,there is a large cross-section of copper for conveying the powernecessary to the functioning of the machine (150 A in alternator mode,600 A on starting) unlike a solution in which the power tracks areintegrated in a band also comprising the electronic power modules.

Cover

According to a first non-limitative embodiment, the cover 70 asillustrated in FIGS. 15 a to 15 c comprises:

positive 71 (B+) and negative 72 (B−) power tracks,

two openings 74 for effecting welding of the tracks 71, 72 with thecorresponding tracks of the power plate 21,

signal tracks 75 affording a connection between the modules and signalconnections 76,

signal connections 76,

grooves or orifices for positive location 77, and

fixing orifices 78 for fixing screws or nuts for example.

The elements of the cover are described in detail below.

-   -   The power tracks 71, 72 are intended to electrically connect the        power tracks 212, 211 of the power interconnection piece 21        providing the connection between the client power connector of        the motor vehicle. The power tracks 71, 72 are moulded on in the        cover 70 and laser welded to the two tracks 212, 211 of the        interconnection piece 21. The electrical connections are made        between these two elements, for example through the opening 74        provided for this purpose. The electrical connections can be        made by welding, in particular by laser welding or weld-brazing,        as well as by brazing or by mechanical contact. In the latter        case, the mechanical contact is obtained for example by fixing        screws for the cover 70 exerting a pressure on the tracks.    -   The signal connections 76 afford a dialogue with the other        electronic boxes of the vehicle. These connections comprise        signal tracks 75 integrated in the cover 70 and connected on the        one hand to the control module 30 and at the other end to the        client signal connector (not shown). The said client signal        connector comprises a cable for connection to a control means        such as for example a computer controlling various functions of        the vehicles such as for example the management of the rotary        electrical machine according to its generator or motor        functions.    -   The grooves or orifices for positive location 77 make it        possible to position the cover 70 correctly on the guides 107 of        the control module 30. The said grooves or orifices thus engage        with guides 107 of the control module 30.

According to a second non-limitative preferential embodiment,illustrated in FIG. 16, the cover comprises:

openings 79 intended to receive fixing means such as studs in place ofscrews.

It also comprises the following elements described in the firstembodiment:

the power tracks 71, 72,

the element 73 for connection to the on-board system,

the two openings 74,

the signal interconnection 75,

the signal connections 76, and

the grooves or orifices 77 for positive location.

It should be noted that the cover 70 as described in the two embodimentsis intended to be a part specific to each client because of the specificlocation and the type of client connector or connectors used.

According to a third non-limitative preferential embodiment, illustratedin FIGS. 17 a and 17 b, the cover is a simple cover that comprisessolely fixing clips 791 for the cover fitting on studs 226 g of thesignal plate 22 fixing the assembly. It no longer comprises any track orconnector. There is only plastics material.

After having seen all the elements that cooperate with the electronicmodules, we describe below their assembly.

As will be seen in detail below, the electronic modules are fixed to therear bearing of the machine in several ways:

Either on the bearing directly (dissipator bearing with fins or waterintegrating or not heat pipes),

or on a non-integrated dissipator (with fins or water integrating or notheat pipes).

1)1^(st) Method of Assembly or Arrangement

According to a first method of assembling the modules, an electronicmodule interfaces with the following elements:

a dissipator bearing 60,

a signal interconnection piece 22 according to the first or secondembodiments,

a power interconnection piece 21 according to the first or secondembodiments,

a cover 70 according to the first or second embodiments.

Thus the 1^(st) method of assembling all the parts described above iseffected in the following manner.

In a first step 1), the electronic module or modules are mounted on thedissipator bearing 60.

The positioning of each module on the dissipator bearing 60 isfacilitated by the two positioning pins 109 a, 109 b, which will besituated opposite each orifice 609 a, 609 b of the corresponding bearing60.

The modules are fixed to the dissipator bearing 60 on the one hand bymeans of an adhesive, for example with glass balls, and on the otherhand mechanically in two different ways.

According to a first non-limitative way, illustrated in FIG. 18, each ofthe modules is fixed by three studs 113. The three studs are inserted inthe corresponding orifices 608 in the said bearing. FIG. 18 shows theassembly of five modules, three power modules 20, a control module 30and an excitation module 40.

According to a second non-limitative preferential way, illustrated inFIG. 24, the fixing is effected by means of:

three studs 226 g that are put in place after the installation of thesignal interconnection plate 22 and that are inserted in thecorresponding orifices 681, 682, 683 in the dissipator bearing 60, and

a screw 226 v that is inserted in the associated orifice 684 in thebearing.

FIG. 23 shows the assembly of four modules, three power modules 10, onecontrol/excitation module.

For the two ways, all the modules are preferentially arranged in thesame plane perpendicular to the rotation axis of the rotor of theelectrical machine, just like the power tracks and the signalconnections, in order to facilitate their assembly.

However, in a variant of what is presented in the previous figures, themodules can be disposed on different planes.

In a second step 2), the signal interconnection plate 22 is mounted onthe electronic modules. Because of this, the said plate is as close aspossible to the modules in order to reduce the length of the signalconnections as far as possible and to prevent plugging problems. In thisway, the signal connections 106 of the modules are short; thus theirdeformation is better controlled (they are less deformable), the saidconnections preferably being flexible.

The signal interconnection plate 22 is fixed to the module/bearingassembly in two different ways corresponding to the two ways of fixingthe modules to the bearing as described previously.

According to a first non-limitative way, illustrated in FIG. 19, theplate 22 is positioned by means of the positioning studs 224, which arepositioned opposite the positioning orifices 601 a and 601 b of thebearing. Thus, by virtue of this positioning:

the connection recesses 221 a are placed opposite the signal connectionelements 106 a of the modules,

the connection recesses 221 b are placed opposite the signal connectionelements 106 b of the modules, and

the fixing lugs 222 are placed opposite the studs 113 of the modules 10.

Next, after pressing, the signal connections 106 a are inserted in theinterconnection orifices 2210 of the metal signal tracks TS, theconnection elements 106 b are inserted in the interconnection orifices2211 of the metal signal tracks TS, and the lugs 222 are fixed to thestuds 113.

According to a second non-limitative preferential way, illustrated inFIG. 24, the plate 22 is positioned on the modules by means of thepositioning pins 224, which are positioned opposite the positioningorifices 610 a and 610 b of the bearing. Thus, by virtue of thispositioning:

the connection recesses 221 a are placed opposite the signal connectionelements 106 a of the modules,

the connection recesses 221 b are placed opposite the signal connectionelements 106 b of the modules,

the stays 225 a and 225 b are placed opposite the support zones 114 ofthe modules, and

the inserts 226 are placed opposite the corresponding orifices 681 to684 in the bearing.

Next, after pressing, the connection elements 106 are inserted in thesaid corresponding recesses 221, the stays 225 bearing on the supportzones 114 of the modules.

The studs 226 g, which are inserted in the orifices 224 in the saidplate 22 and 681, 682, 683 of the dissipator bearing 60, are then fixed.The studs bear on the said plate and consequently on theplate/modules/bearing assembly so as to afford better mechanicalstrength. In the same way, the screw 226 v is screwed into therespective corresponding orifices 226 and 684 in the plate 22 andbearing 60.

Thus the signal interconnection plate 22 is produced so as to exert apressure on the power modules 20 and the other modules 30, 40 in orderto guarantee their holding throughout the life of the rotary electricalmachine.

In a non-limitative embodiment, the material of the said plate is PPS(phenylene polysulphide) plastic containing glass fibres.

Thus, according to these two ways, the signal plate is deformed in orderto exert a pressure on the modules, the deformation preferably beingapproximately 0.3 mm. In this way, the detachment of the modules isprevented and stresses on the welds of the tongues are avoided.

In a third step 3), the power interconnection plate 21 is mounted on thebearing/modules/signal plate assembly. The power interconnection plate21 is fixed above the signal interconnection plate 22.

The power plate 21 is fixed in two different ways.

According to a first non-limitative way, illustrated in FIG. 20, thepower plate 21 is placed on the signal plate 22 so that:

the fixing lugs 215 are placed opposite the studs 113 of the modules 22,the said studs making it possible to position the said plate 21,

the power terminals 2120, 2110 are placed opposite the correspondingtracks of the module 103, 104,

In the case of a brush holder, it is positioned so that it is insertedin the recess 605 and the brush cage protector in the recess 603 of thebearing.

Next, after pressing, the fixing lugs 215 are fixed on the studs 113,the power terminals 2120, 2110 bear respectively on the ends of thetracks 103, 104 of the modules.

According to a second non-limitative preferential way, illustrated inFIG. 25, the power plate 21 is placed on the signal plate 22 so that:

the inserts 219 are placed opposite the studs 226 g, the said orificesand studs serving as a positive location device,

the lug 218 is placed opposite the holding clip 227 of the signal plate22.

Next, after pressing, the orifices 219 are inserted on the studs 226 gand the lug 218 snaps in the clip 227, and

the orifice 219 c is placed opposite a third stud 226 g.

In a last step, the cover 70 is mounted on the assembly. In this way,the cover 70 forms a shroud for the rear bearing of the machine.

The cover 70 is fixed in two different ways.

According to a first non-limitative way, illustrated in FIGS. 21 and 22,the cover 70 is placed on the power plate 21 so that the grooves 77 ofthe cover are situated opposite the guides 107 of the control module 30.These guides and grooves serve as a positive location device.

Next, after pressing, the said grooves are inserted in the said guidesso that:

contact is established between the signal tracks 75 of the cover 70 andthe tongues 106 c of the control module 30, and

contact is established between the power tracks 71 (B+), 72 (B−) of thecover and respectively the power tracks 212, 211 of the power plate 21.

Finally, after installation of the cover, the electrical connection ismade between the tracks 71, 72 of the cover and the tracks 212, 211 bylaser welding via the openings 74.

The cover is fixed by three screws or nuts 78.

According to a second non-limitative preferential way, illustrated inFIG. 26, the cover 70 is placed on the power plate 21 in the same way asthe first way with a view to establishing the electrical contacts. Inaddition, the openings 79 are placed above the three studs 226 g thatfix the electronic assembly.

Next, after pressing, the cover 70 is fixed by means of the said studsto the electronic assembly (bearing/modules/interconnection plates).

In this case, the cover 70 bears on all the elements of the arrangementand thus ensures sufficiently strong support in order both to immobilisethe power plate 21 on the dissipator bearing and to provide thenecessary electrical contacts.

Thus, as can be seen, according to this first assembly mode, theelectronic modules 10, the signal interconnection piece 22, the powerinterconnection piece 21 and the dissipator occupy respectively first,second, third and fourth planes all parallel to one another, and theplanes are superimposed in the following order starting from the planeclosest to the rear bearing of the machine:

fourth plane,

first plane,

second plane, and

third plane.

Thus the power interconnection piece 21 is independent of the electronicmodules and is connected to the said modules in particular only by itspower electrical terminals.

The same applies to the signal interconnection piece 22, which isconnected to the said modules in particular only by its signalconnections 106.

2)2^(nd) Assembly Mode or Arrangement

According to a second module assembly mode, or arrangement, anelectronic module interfaces with the following elements:

a dissipator 80,

a signal interconnection piece 22 according to the third embodiment,

a power interconnection piece 21 according to the third embodiment,

a cover 70, according to the third embodiment.

Thus the second method of assembling all the parts described above iseffected as follows.

It should be noted that, in the example taken for this assembly method,there exist four modules that are fixed to the dissipator 80. Threepower modules 20 and one control/excitation module 30.

In a first step 1), illustrated in FIG. 27 a, the modules are positionedon the top face of the dissipator 80 so as to fix them.

The positioning takes place by means of the positioning pins 109 a and109 b, which are placed opposite the orifices 810 of the dissipator 80,and during the positioning the insert 120 of each module comes to bepositioned opposite each associated orifice 804 in the dissipator 80.

Subsequently the fixing is carried out by means of:

screws 1150 that are inserted in the fixing orifices 115 of the modulesand the corresponding orifices 804 of the dissipator 80. These fixingscrews also make it possible to connect the modules to earth via theinsert 120, and

the connector 116 of the control/excitation module 30, which is screwedinto the associated orifice 807 of the dissipator, by means of a viascrew.

During assembly,

the electrical protection means 126 of the modules are inserted in therecesses 109 of the dissipator provided for this purpose.

In addition, the modules are also bonded to the dissipator 80 by meansof an adhesive, such as a glass ball adhesive.

It should be noted that, prior to the fixing of the control/excitationmodule 30 to the dissipator 80, the brush holder 50 was fixed to thesaid module by means of the screw 117 a provided for this purpose. Inanother variant, it is possible to fix it after the installation of thesaid module 30 on the dissipator 80.

In a second step 2), illustrated in FIG. 28, the power plate 21 ispositioned on the bottom face of the dissipator so as to fix the saidplate 21 to the said dissipator 80.

The positioning is effected by means of:

means 214 d of positioning the said plate 21 that come opposite theassociated positioning orifices 808 in the dissipator, and

the fixing terminal 215 d, which comes opposite the electricalconnection orifice 805.

The fixing of the said plate 21 on the dissipator 80 is effected bymeans of:

the two positioning means 214, which are placed in the correspondingorifices 808 in the dissipator,

the fixing terminal 215 d, which is plugged into the electricalconnection orifice 805, and

the four force stays 213 d, which are placed opposite the correspondingsupports 814 of the dissipator.

During assembly,

phase protection means 211 d are integrated in the recesses 812 providedfor this purpose in the dissipator.

Thus, as can be seen in FIG. 28:

the means 221 d will protect the phase tongues of the stator,

the axial tongues of the electrical terminals 215 d are then oppositethe corresponding positive tracks 103 (B+) of each electronic module 10,which will make it possible to establish an electrical connectionbetween the said tracks 103 and the positive track 221 d (B+) of thepower plate 21, and

the electrical insert 216 d integrated in the terminal 215 d makes itpossible to earth the dissipator 80.

In a third step 3), illustrated in FIG. 29, the signal interconnectionplate 22 is positioned on the said electronic modules 10 so as to fixit.

It should be noted that the signal plate 22 is pre-positioned(pre-guided) by virtue of two protection pins 107 of two electronicmodules 10, the said pins being the furthest away from each other inorder to pre-guide well.

The positioning is effected by means of:

the two hollowed-out protuberances 230 serving for pre-guidance andwhich are pre-positioned on two positioning pins or guides 107 belongingto electronic modules.

Then, subsequently, it is possible to position the signal plate 22 bymeans of the positioning pins 224 in the corresponding orifices 811 ofthe dissipator 80.

During assembly, there are:

the connection recesses 221 a that are placed opposite the signalconnection elements 106 a of the modules,

the connection recesses 221 b that are placed opposite the signalconnection elements 106 b of the modules,

the stays 225 a and 225 b that are placed opposite the support zones119, 114 respectively of the modules, and

the inserts 226 that are placed opposite the corresponding orifices 806of the dissipator.

The fixing takes place by means of:

insulated hollow rivets 2101 d associated with the inserts 210 d of thepower plate. These rivets 2101 d inside the inserts allow on the onehand an assembly of the signal plate and on the other hand an insulationof the mass of the dissipator with respect to the mass of the bearing,and finally the creation of an electronic sub-assembly (the two plates,the dissipator and the electronic modules) pre-assembled so that, duringassembly on the bearing, by means of screws or studs, after welding thesignal connections 106 with the signal plate 22, there are no additionalforces that would risk mechanically stressing the said welds.

Next, after pressing, the signal tongues 106 are inserted in the saidcorresponding interconnection orifices 2210, 2211, the stays 225 bearingon the support zones 119, 114 of the modules.

It should also be noted that the housings 231 of the signal platecomprise in the example illustrated in FIG. 29 a capacitor associatedwith each of the power modules 20, which is connected firstly to thepositive track 103 (B+) of the associated module and secondly to thenegative track 104 (B−) of the said associated module.

In addition, preferentially, it is possible to effect a tin or laserwelding, or to deposit a resin plus polymerisation in the connectionrecesses 221 a and 221 b of the signal tongues 106 in order inparticular to protect them from salt spray.

In a fourth step 4), illustrated in FIG. 30 a, the whole of theelectronics thus obtained are positioned on the rear bearing 90 of themachine.

Fixing takes place by means of:

four studs 226 g or screws in the rear bearing 90 by means of theinserts 226 of the signal plate 22, 210 d of the power plate 21 and 806of the corresponding dissipator 80. The studs bear on the same plate andconsequently on the plate/dissipator/bearing assembly so as to create anelectronic assembly on the bearing. In the same way, the screw 226 v isscrewed in the respective corresponding orifices 226 and 807 of theplate 22 and dissipator 80.

FIG. 30 b is a view in section along the plane X-Y shown in FIG. 30,showing an entire assembly of the main parts cited above. It shows inparticular:

the bearing 90,

the signal interconnection plate 21,

the dissipator 80,

the signal interconnection plate 22,

a rivet 2101 d, and

a fixing stud 226 g.

It should be noted that, prior to the electronic assembly, the rearbearing 90 of the machine is fixed to the front bearing (not shown) ofthe said machine by means of four tie rods in orifices 903, the orificesbeing illustrated in FIG. 30 c of the bearing 90. The tie rods are thusscrewed before the electronic assembly, which makes it possible toposition the phases of the stator in advance and therefore to facilitatethe assembly of the electronic sub-assembly with the said phases.

The rear bearing comprises in particular:

a positioning orifice 901 configured so as to receive the positioningpin 1151 of the control/excitation module 30, which allows precisepositioning of the position sensors with respect to the bearing, and

a referencing orifice 902 in which the pin 212 d of the power plate 21is inserted.

The phase hooks 105 cr are also welded to the phases of the stator(standard wires or using a thimble).

Finally, in a fifth step 5), the plastic cover 70 is put in place bymeans of fixing clips that are snapped onto the studs.

It should be noted that the steps specified above can be performed in adifferent order. For example, the second step can of course be performedbefore the first step (FIG. 27 b illustrates this case) or after thethird step.

Thus the second assembly method has the following advantages:

Firstly, the assembly of the entire electronic part (modules, power andsignal plates) takes place outside the rear bearing so that it ispossible to test the electronics before assembly on the machine; in thisway only the electronics that function in the said machine areintegrated, which saves time in terms of process, and makes it possibleto have two independent processes and therefore not to modify the“process” method of standard machine assembly that already exists;

Secondly, the assembly of the electronic part can take place after theassembly of the rear bearing of the machine on the front bearing, ormore particularly after the fitting of the tie rods fixing the bearings,which will then be covered by the electronics;

Thirdly, the performance with regard to thermal cooling is improvedbecause of the axial air flow added to the radial air flow. There is areduction in pressure drops with an axial air inlet;

Fourthly, the cover is now no more than a simple plastic cover. Thereare no moulded-on tracks in the cover, the power tracks and the signaltracks being integrated respectively in the power plate and in thecontrol/excitation module, which makes it possible to limit the numberof interconnection welds to be carried out;

Fifthly, the earth plane is implemented by the dissipator. There istherefore a reduction in the resistance and inductance of the internalpower circuit between the client two-phase power connector and the powermodule because of the proximity of the positive-polarity track (B+) ofthe power plate (21) to the dissipator mass;

Sixthly, the earth plane is implemented by the dissipator, so that thereis a saving in axial space. In this way an existing part is used forconveying current.

Thus, according to this second assembly method, the electronic modules10, the signal interconnection piece 22, the power interconnection piece21 and the dissipator occupy respectively first, second, third andfourth planes all parallel to one another, and the planes aresuperimposed in the following order, starting from the plane closest tothe rear bearing:

third plane,

fourth plane,

first plane, and

second plane.

Thus the power interconnection piece 21 is independent of the electronicmodules and is connected to the said modules in particular only by itselectrical power terminals.

The same applies to the signal interconnection piece 22, which isconnected to the said modules in particular only by its signalconnections 106.

Thus all the four parts form an independent electronic sub-assembly of abearing of the machine.

It should be noted that the two assembly methods have the advantage ofusing the maximum surface available on the rear of the machine for themodules by virtue of the stacking of the various elements for the powerand signal interconnections, unlike a solution in which the power andsignal interconnection tracks occupy surface on the rear of the machineto the detriment of the modules.

It should be noted that the signal interconnection plate 22 according tothe various embodiments described above can be used when there is nopower plate 21. For example with modules themselves effecting theirpower interconnection.

As for the power interconnection plate 21 according to the variousembodiments described previously, it can also be used without the signalplate 22. For example, with an electronic card PCB effecting the signalinterconnection.

The assembly according to all the embodiments presented above has thefollowing additional advantages:

it avoids stacking all the tracks on one another, a stack not beingpropitious to good holding in position of the tracks,

it comprises means of fixing to the dissipator or to the dissipatorbearing that are not concentrated on the periphery of the saiddissipator or bearing, so that there exists a distribution of forces soas to withstand the mechanical vibrations well,

it enables the various components (interconnection plates and modules)to be in different planes and perpendicular to the rotation axis of themachine, so that it creates more space for the power tracks, which givesrise to a reduction in the resistivity of the said tracks. Thus thisassembly makes it possible to convey higher power,

it makes it possible to use in an optimum fashion the space availablefor the electronic modules on the rear bearing of the machine, thevarious components (interconnection plates and modules) being ondifferent planes and perpendicular to the rotation axis of the machine.

1. An assembly of electronic components for a rotary electrical machineand power and signal interconnection pieces cooperating with saidelectronic components in order respectively to distribute power to saidelectronic components and convey control signals between electroniccomponents for the functioning of the rotary electrical machine,wherein: the electronic components are disposed in at least oneelectronic module disposed on a first plane, said at least oneelectronic module comprising a housing defined by a top face and abottom face and at least three lateral faces; the signal interconnectionpiece is disposed on a second plane parallel to the first plane; and thepower interconnection piece is disposed on a third plane parallel to thefirst plane; the power and signal interconnection pieces beingindependent of each other and independent of said at least oneelectronic module.
 2. The assembly according to claim 1, wherein thesecond and third planes are connected with the first plane byinterconnection elements.
 3. The assembly according to claim 1, whereinsaid assembly comprises a dissipator integrated or not in a bearing ofthe rotary electrical machine, said dissipator being on a fourth planeparallel to the other planes.
 4. The assembly according to claim 1,wherein: the at least one electronic module comprising electroniccomponents is mounted on the top face of a dissipator, the signalinterconnection piece is mounted on the top face of the housing of saidat least one electronic module, and the power interconnection piece ismounted on the signal interconnection piece, the whole forming anelectronic sub-assembly.
 5. The assembly according to claim 1, whereinthe planes of said modules, of the signal interconnection piece, of thepower interconnection piece and of a dissipator are superimposed in thefollowing order: fourth plane, first plane, second plane, and thirdplane.
 6. The assembly according to claim 1, wherein the signalinterconnection piece comprises electrically conductive signal tracks,said electrically conductive signal tracks comprising signalinterconnection elements, and in that the second plane is connected tothe first plane by said signal interconnection elements, which areintended to cooperate with signal connections of at least one electronicmodule.
 7. The assembly according to claim 1, wherein the powerinterconnection piece comprises at least one power track provided withelectrical power terminals, and in that the third plane is connected tothe first plane by said power terminals, which are intended to cooperatewith a power track of at least one electronic module.
 8. The assemblyaccording to claim 1, wherein an electronic module comprises orificesfor receiving fixing means for fixing the module to a dissipator.
 9. Theassembly according to claim 1, wherein an electronic module comprisessupport zones for fixing it to a dissipator by pressing.
 10. Theassembly according to claim 1, wherein the signal interconnection piececomprises at least one pre-assembly device for fixing the powerinterconnection piece.
 11. The assembly according to claim 1, whereinthe signal interconnection piece also comprises fixing devices on the atleast one electronic module, disposed on the outside and insidediameters of said piece.
 12. The assembly according to claim 1, whereinthe signal interconnection piece also comprises support devices on anelectronic module, disposed on the outside and inside diameters of thepiece for fixing said module to a dissipator of the rotary electricalmachine by pressing, said support devices preferably being stays withouta sharp edge.
 13. The assembly according to claim 1, wherein the powerinterconnection piece comprises fixing devices for fixing to anelectronic module, said fixing devices extending radially on theexternal periphery of said piece.
 14. The assembly according to claim 1,wherein the power interconnection piece also comprises pre-assemblydevices on a signal interconnection piece.
 15. The assembly according toclaim 1, wherein the power interconnection piece also comprises insertsfor receiving fixing means for fixing on the rotary electrical machine.16. The assembly according to claim 1, wherein the power interconnectionpiece also comprises support devices for supporting said piece on adissipator of the rotary electrical machine.
 17. The assembly accordingto claim 1, wherein the power interconnection piece also comprisesinterleaved and concentric power tracks.
 18. The assembly according toclaim 1, wherein the power interconnection piece comprises at least onepositive power terminal and at least one negative power terminal for anelectronic module.
 19. The assembly according to claim 1, wherein thepower interconnection piece has a base plate comprising at least onerecess for an electrical connection of a power interconnection trackwith a cover.
 20. The assembly according to claim 1, wherein a cover isdisposed on a fifth plane different from the other planes and preferablycomprises grooves intended to cooperate with guides of an electronicmodule.
 21. The assembly according to claim 20, wherein the covercomprises signal tracks intended to cooperate with signal connections ofan electronic module and/or power tracks intended to cooperate withpower tracks of the power interconnection piece.
 22. The assemblyaccording to claim 20, wherein the cover comprises openings forproducing contacts between signal tracks of the cover, power tracks ofthe cover, and respectively signal tracks of an electronic module, andpower tracks of the power interconnection piece.
 23. The assemblyaccording to claim 1, wherein: the at least one electronic modulecomprising electronic components is mounted on the top face of adissipator, the signal interconnection piece is mounted above the atleast one electronic module, and the power interconnection piece ismounted on the bottom face of said dissipator, the whole forming anelectronic sub-assembly.
 24. The assembly according to claim 1, whereinthe planes of said modules, of the signal interconnection piece, of thepower interconnection piece and of a dissipator are superimposed in thefollowing order: third plane, fourth plane, first plane, and secondplane.
 25. The assembly according to claim 23, wherein the dissipator isan attached dissipator.
 26. The assembly according to claim 23, whereinthe signal interconnection piece comprises electrically conductivesignal tracks, said tracks comprising signal interconnection elements,and in that the second plane is connected to the first plane byte saidsignal interconnection elements, which are intended to cooperate withsignal connections of at least one electronic module.
 27. The assemblyaccording to claim 23, wherein the power interconnection piece comprisesat least one power track provided with electrical power terminals, andin that the second plane is connected to the first plane by said powerterminals, which are intended to cooperate with a power track of atleast one electronic module.
 28. The assembly according to claim 23,wherein an electronic module comprises an end of a power trackconfigured so as to establish a connection with a fixing terminal of thepower interconnection piece.
 29. The assembly according to claim 23,wherein an electronic module comprises a free end of a power track thatis perpendicular to the bottom face of the module.
 30. The assemblyaccording to claim 23, wherein the power interconnection piece alsocomprises at least one insert for receiving a hollow rivet and effectinga pre-assembly with an electronic module and a signal interconnectionpiece and a dissipator.
 31. The assembly according to claim 23, whereinthe power interconnection piece also comprises means of positioning onthe bearing of the rotary electrical machine, said means extending overa bottom face of said piece.
 32. The assembly according to claim 23,wherein the power interconnection piece also comprises at least oneforce stay for an axial deformation of said piece.
 33. The assemblyaccording to claim 23, wherein the power interconnection piece alsocomprises a metal insert so as to effect an electrical connection with anegative power track.
 34. The assembly according to claims 23, whereinthe power interconnection piece also comprises a collar intended tocover air outlet openings of the bearing of the rotary electricalmachine so as to guide the discharged air and to attenuate any loopingof air.
 35. The assembly according to claim 23, wherein a cover isdisposed on a fifth plane different from the other planes.
 36. Theassembly according to claim 1, wherein an electronic module comprisespositioning devices for assembly on a dissipator.
 37. The assemblyaccording to claim 1, wherein an electronic module comprises powerconnection ends that are all disposed in the vicinity of a first face ofthe housing.
 38. The assembly according to claim 37, wherein said powerconnection ends are all in the vicinity of the outside diameter of therotary electrical machine.
 39. The assembly according to claim 1,wherein an electronic module also comprises power electronic componentsthat form at least one bridge rectifier arm, an arm being intended tocooperate with a phase of the stator.
 40. The assembly according toclaim 1, wherein an electronic module also comprises control elementsfor power electronic components.
 41. The assembly according to claim 1,wherein an electronic module also comprises control electroniccomponents for power electronic components for the functioning of therotary electrical machine.
 42. The assembly according to claim 1,wherein an electronic module also comprises electronic componentsintended for the electrical supply of the excitation winding of therotor.
 43. The assembly according to claim 1, wherein the housing of anelectronic module is substantially triangular in shape.
 44. The assemblyaccording to claim 1, wherein an electronic module comprises a faceoriented towards the outside diameter of the rotary electrical machine,which is in the form of an arc of a circle.
 45. The assembly accordingto claim 1, wherein an electronic module comprises at least one powerconnection in the form of at least one phase track intended to beconnected to a phase of the stator of the rotary electrical machine. 46.The assembly according to claim 45, wherein a phase track comprises anend placed between two power electrical conductors.
 47. The assemblyaccording to claim 1, wherein the bottom face of an electronic modulecarrying the electronic components and the power connections is fixed toa thermally conductive plate by means of an electrically insulatingadhesive.
 48. The assembly according to claim 1, wherein an electronicmodule also comprises signal connection elements that are in the sameplane perpendicular to the bottom face of the module, said plane passingessentially through a rotor rotation axis of the rotary electricalmachine.
 49. The assembly according to claim 1, wherein an electronicmodule also comprises signal connection elements that are aligned on thesame lateral face of the housing on which the ends of the powerconnections are disposed.
 50. The assembly according to claim 1, whereinthe signal interconnection piece comprises interconnection devices thatare orifices.
 51. The assembly according to claim 1, wherein the signalinterconnection piece comprises a base plate made from insulatingmaterial that overmolds signal tracks.
 52. The assembly according toclaim 1, wherein the signal interconnection piece comprisesinterconnection devices, the axes of which are in a first planeperpendicular to a second plane on which all the signal tracks aredisposed, said first plane passing through a rotor rotation axis of therotary electrical machine.
 53. The assembly according to claim 1,wherein the signal interconnection piece also comprises interconnectiondevices disposed on the external periphery of said piece.
 54. Theassembly according to claim 1, wherein the signal interconnection piecealso comprises metal signal tracks configured in the form of arcs of acircle essentially concentric with respect to a rotation axis of therotor of the rotary electrical machine.
 55. The assembly according toclaim 1, wherein the signal interconnection piece also comprisespositioning studs for assembly on a dissipator of the rotary electricalmachine.
 56. The assembly according to claim 1, wherein the signalinterconnection piece also comprises inserts for fixing to a dissipatorof the rotary electrical machine and/or devices for pre-positioning thepiece on several electronic modules.
 57. The assembly according to claim1, wherein the power interconnection piece also comprises powerterminals extending towards the external periphery of said piece. 58.The assembly according to claim 1, wherein the power interconnectionpiece also comprises power terminals with curved free ends.
 59. Theassembly according to claim 1, wherein the power interconnection piecealso comprises a base plate.